Temperature Controlled Cargo Containers

ABSTRACT

Temperature controlled cargo containers may include thermal masses conditioned to temperatures above and/or below a target temperature. Example thermal masses may include plates including phase change materials, such as eutectic materials. One or more fans and flapper valves may be selectively operated to circulate air in the cargo container across one or more of the thermal masses to maintain the temperature within the cargo container within a prescribed temperature band. Some example temperature controlled cargo containers may include refrigeration units and/or heaters for regenerating the thermal masses when receiving power from an external power source and/or may include one or more rechargeable batteries for providing power during transport or storage independent of external power sources.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.12/705,803, filed Feb. 15, 2010, U.S. Provisional Application No.61/244,232, filed Sep. 21, 2009, and PCT/US10/49246, filed Sep. 17,2010, which are incorporated by reference.

BACKGROUND

The present disclosure is directed to containers for controlling thetemperature of a product placed therein and methods of using temperaturecontrolled cargo containers.

The following documents may be related to cargo containers and/ortemperature controlled transport: U.S. Pat. Nos. 3,180,403; 4,462,461;5,561,986; 6,020,575; 6,281,797; 6,694,765; 6,865,516; and 7,501,944;and U.S. Patent Application Publication No. 2007/0175236, and areincorporated by reference into this Background section.

SUMMARY

Some example temperature controlled cargo containers according to thepresent disclosure may include one or more thermal masses conditioned totemperatures above and/or below a target temperature. Example thermalmasses may include plates including phase change materials, such aseutectic materials. One or more fans may be selectively operated tocirculate air in the cargo container across one or more of the thermalmasses to maintain the temperature within the cargo container within aprescribed temperature band. Some example temperature controlled cargocontainers may include refrigeration units and/or heaters forregenerating the thermal masses while receiving power from an externalpower source and/or may include one or more rechargeable batteries forproviding power during transport or storage independent of externalpower sources.

In an aspect, a method of controlling the temperature of a product mayinclude placing a product in an interior storage space of a container,where the container includes a warm phase change plate and a cold phasechange plate; and changing a temperature of the interior storage spaceby causing airflow across at least one of the warm phase change plateand the cold phase change plate.

In a detailed embodiment, changing the temperature of the interiorstorage space may include sensing a temperature associated with theproduct; if the temperature associated with the product is above atarget temperature range, operating a cooling fan associated withcausing air flow across the cold phase change plate; and if thetemperature associated with the product is below the target temperaturerange, operating a warming fan associated with causing air flow acrossthe warm phase change plate. In a detailed embodiment, operating thecooling fan associated with the cold phase change plate may includedrawing air from the interior storage space through a separator wall atleast partially interposing the interior storage space and the coldphase change plate, flowing the air through an open flapper valve pastthe cold phase change plate, and discharging the air into the interiorstorage space. In a detailed embodiment, operating the warming fanassociated with the warm phase change plate may include drawing air fromthe interior storage space through a separator wall at least partiallyinterposing the interior storage space and the warm phase change plate,flowing the air through an open flapper valve and past the warm phasechange plate, and discharging the air into the interior storage space.

In a detailed embodiment, a method may include, prior to changing atemperature of the interior storage space, conditioning at least one ofthe warm phase change plate and the cold phase change plate. In adetailed embodiment, conditioning the cold phase change plate mayinclude operating a refrigeration unit to cause freezing of a cold phasechange solution within the cold phase change plate. In a detailedembodiment, conditioning the warm phase change plate may includeoperating a heater to melt a warm phase change solution within the warmphase change plate.

In a detailed embodiment, changing a temperature of the interior storagespace may include directing the airflow along a first side of the atleast one of the warm phase change plate and the cold phase change platein a first direction and directing the airflow along a second side ofthe at least one of the warm phase change plate and the cold phasechange plate in a second direction, where the second direction may besubstantially opposite the first direction.

In a detailed embodiment, a method may include reducing naturalcirculation flow across at least one of the warm phase change plate andthe cold phase change plate. In a detailed embodiment, reducing naturalcirculation flow across at least one of the warm phase change plate andthe cold phase change plate may include providing flapper valves and anair trap associated with at least one of the warm phase change plate andthe cold phase change plate. In a detailed embodiment, providing the airtrap may include providing at least one of a downwardly extending wallat least partially interposing the warm phase change plate and theinterior storage space, and an upwardly extending wall at leastpartially interposing the cold phase change plate and the interiorstorage space.

In a detailed embodiment, a method may include transporting thecontainer from a first location to a second location while the productremains within the interior storage space.

In an aspect, a method of storing a product in a container may includeoperating a refrigeration system to cool a cold phase change plateassociated with an interior storage space of a container; operating aheater to heat a warm phase change plate associated with the interiorstorage space; placing a product in the interior storage space;measuring a temperature associated with the interior storage space; andselectively operating at least one fan to cause airflow across at leastone of the cold phase change plate and the warm phase change plate ifthe temperature associated with the interior storage space departs froma predetermined temperature range.

In a detailed embodiment, a method may include, prior to operating therefrigeration system and operating the heater, connecting therefrigeration system and the heater to a first external source ofelectrical power. In a detailed embodiment, a method may include, afteroperating the refrigeration system and operating the heater,disconnecting the refrigeration system and the heater from the firstexternal source of electrical power. In a detailed embodiment, a methodmay include, after disconnecting the refrigeration system and the heaterfrom the first external source of electrical power, loading thecontainer into a vehicle. In a detailed embodiment, loading thecontainer into a vehicle may include loading the refrigeration systemand the heater into the vehicle, the refrigeration system and the heaterbeing mounted to the container. In a detailed embodiment, a method mayinclude transporting the container from a first location to a secondlocation using the vehicle; and, at the second location, conditioning atleast one of the cold phase change plate and the warm phase changeplate. In a detailed embodiment, a method may include, prior toconditioning the at least one of the cold phase change plate and thewarm phase change plate at the second location, connecting at least oneof the refrigeration unit and the heater to a second external source ofelectrical power. In a detailed embodiment, a method may include, afterthe refrigeration unit and the heater have been disconnected from thefirst external source of electrical power and prior to connecting therefrigeration unit and the heater to the second external source ofelectrical power, operating the at least one fan using power suppliedfrom a rechargeable battery associated with the container.

In an aspect, a temperature controlled container may include an interiorspace for receiving a product; a warm phase change plate arranged forselective heat exchange with the interior space; and a cold phase changeplate arranged for selective heat exchange with the interior space.

In a detailed embodiment, the warm phase change plate and the cold phasechange plate may be at least partially separated from the interior spaceby a separator wall. In a detailed embodiment, a temperature controlledcargo container may include a first fan selectively operable to causeforced convection between the interior space and the warm phase changeplate; and a second fan selectively operable to cause forced convectionbetween the interior space and the cold phase change plate. In adetailed embodiment, the cold phase change plate may include a firstphase change solution, and the warm phase change plate may include asecond phase change solution. In a detailed embodiment, a melting pointof the second phase change solution may be higher than a melting pointof the first phase change solution. In a detailed embodiment, a targettemperature range may lie between the melting point of the first phasechange solution and the melting point of the second phase changesolution. In a detailed embodiment, the melting point of the first phasechange solution may be about −5.5° C., and the melting point of thesecond phase change solution may be about 15° C. In a detailedembodiment, the target temperature range may be about 2-8° C.

In an aspect, a container may include an interior space for receiving aproduct; a phase change plate arranged for selective heat exchange withthe interior space; and a trap arranged to reduce natural convectionheat transfer between the phase change plate and the interior spacewhile allowing forced convection heat transfer between the phase changeplate and the interior space.

In a detailed embodiment, the phase change plate may include a coldphase change plate and/or the trap may include an upwardly extendingwall at least partially interposing the interior space and the coldphase change plate. In a detailed embodiment, the trap may include aP-trap. In a detailed embodiment, a container may include a fanconfigured to cause air flow from the interior space, across the coldphase change plate, and into the interior space.

In a detailed embodiment, the phase change plate may include a warmphase change plate and/or the trap may include a downwardly extendingwall at least partially interposing the interior space and the warmphase change plate. In a detailed embodiment, the trap may include aP-trap. In a detailed embodiment, a container includes a fan configuredto cause air flow from the interior space, across the warm phase changeplate, and into the interior space.

In an aspect, a container may include a phase change plate including afirst side and a second side and/or a flow path arranged to directairflow along the first side in a first direction and then along thesecond side in a second direction, where the second direction may besubstantially opposite the first direction.

In a detailed embodiment, the first side may be substantially oppositethe second side. In a detailed embodiment, a container may include atleast one fan configured to cause the airflow through the flow path. Ina detailed embodiment, the phase change plate may be at least partiallyseparated from an interior storage space of the container by a wall.

In a detailed embodiment, the phase change plate may include at leastone augmented surface. In a detailed embodiment, the augmented surfacemay include at least one internally extending fin.

In an aspect, a shipping system may include a container including aninterior space for receiving a product, a warm phase change platearranged for selective heat exchange with the interior space, and a coldphase change plate arranged for selective heat exchange with theinterior space; a refrigeration system mounted to the container andconfigured to cool the cold phase change plate; and a heating systemconfigured to heat the warm phase change plate.

In a detailed embodiment, a shipping system may include a data loggerconfigured to record data pertaining to the container. In a detailedembodiment, the data may include a temperature associated with theinterior space.

In a detailed embodiment, the warm phase change plate may include a coldphase change material having a melting point of about −5.5° C. In adetailed embodiment, the cold phase change plate may include a warmphase change material having a melting point of about 15° C. In adetailed embodiment, the heating system may include at least oneelectrical resistance heater in thermal communication with the warmphase change plate.

In an aspect, a container for shipping pharmaceuticals may include awarm phase change plate and/or a cold phase change plate.

In a detailed embodiment, the container may include an interior storagespace for pharmaceuticals, the interior storage space being in selectivethermal communication with the warm phase change plate and/or the coldphase change plate. In a detailed embodiment, a container may include awarming fan configured to cause airflow across the warm phase changeplate and/or a cooling fan configured to cause airflow across the coldphase change plate. In a detailed embodiment, the cold phase changeplate may include a cold eutectic material having a melting point ofabout −5.5° C. and/or the warm phase change plate may include a warmeutectic material having a melting point of about 15° C. In a detailedembodiment, a container a refrigeration system arranged to cool the coldphase change plate and/or a heater arranged to heat the warm phasechange plate.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description refers to the following figures in which:

FIG. 1 is an isometric view of an example temperature controlled cargocontainer;

FIG. 2 is an overhead cross-sectional view of an example temperaturecontrolled cargo container;

FIG. 3 is an elevational cross-sectional view of an example temperaturecontrolled cargo container;

FIG. 4 is an elevational cross-sectional view of an example temperaturecontrolled cargo container with open flapper valve;

FIG. 5 is an elevational cross-sectional view of an example temperaturecontrolled cargo container with closed flapper valve;

FIG. 6 is an elevational cross-sectional view of an example temperaturecontrolled cargo container;

FIG. 7 is an elevational cross-sectional view of an example temperaturecontrolled cargo container with open flapper valve;

FIG. 8 is an elevational cross-sectional view of an example temperaturecontrolled cargo container with closed flapper valve;

FIG. 9 is a cross-sectional view of a wall of an example temperaturecontrolled cargo container;

FIG. 10 is cross-sectional view of an example phase change plate for atemperature controlled cargo container;

FIG. 11 is a schematic diagram of an example refrigeration system for atemperature controlled cargo container;

FIG. 12 is a schematic diagram of an example electrical system for atemperature controlled cargo container;

FIG. 13 is a schematic diagram illustrating an example temperaturecontrolled cargo container configured for use with external conditioningsources;

FIG. 14 is a is a schematic diagram illustrating an example temperaturecontrolled cargo container configured for use with removable phasechange plates; and

FIG. 15 is a perspective view of two example temperature controlledcargo containers on an aircraft pallet; all arranged in accordance withat least some aspects of the present disclosure.

DETAILED DESCRIPTION

The present disclosure includes, inter alia, temperature controlledcargo containers and methods for using temperature controlled cargocontainers.

The present disclosure contemplates that some products (e.g.,pharmaceutical products) may be transported (e.g., by ground, sea,and/or air modes) and may be exposed to ambient conditions outside of anallowable product temperature range during such transportation and/orduring storage. Temperature excursions outside of the allowable producttemperature range may detrimentally affect a product, such as byreducing the efficacy and/or shelf life of a pharmaceutical product.

Some example temperature controlled cargo containers according to thepresent disclosure may be configured to maintain a product locatedtherein within an allowable product temperature range while thetemperature controlled cargo container is exposed to various ambientconditions. For example, some example temperature controlled cargocontainers may be configured to maintain pharmaceutical products withinan interior storage space at about 5° C. (e.g., between about 2° C. andabout 8° C.) during ground, sea, and/or air transportation and/or duringtemporary and/or long-term storage. Some example temperature controlledcargo containers may maintain an interior storage space at about 5° C.for about 72 hours when the ambient temperature is about 30° C. whileoperating independently from external power sources and/or coolingsources. Some example temperature controlled cargo containers maymaintain an interior storage space at about 5° C. during ambienttemperature excursions, such as from about −40° C. to about +60° C.

Referring to FIGS. 1-8, an example temperature controlled cargocontainer 100 according to the present disclosure may include agenerally rectangular enclosure 101 and/or an equipment section 111,which may be disposed substantially adjacent to enclosure 101. Enclosure101 may include walls 102 and/or a door 103, which may be pivotablyaffixed to walls 102 by a hinge 109. In some example embodiments, door103 and equipment section 111 may be disposed on generally oppositesides of enclosure 101. A door sealing assembly associated with door 103may include thermal breaks on one or both sides of the door/enclosureinterface, redundant compression bulb gaskets, and/or multi-point (e.g.,three-point) draw latches which may fix the gasket compression depth.Enclosure 101 and/or equipment section 111 may be mounted on a palletbase 113, which may facilitate handling of temperature controlled cargocontainer 100 by forklifts and/or other material handling equipment, forexample. An interior storage space 104 within enclosure 101 (which maybe accessible via door 103) may receive a product 106, such as apharmaceutical product.

Some example temperature controlled cargo containers 100 may include atleast one cold thermal mass and/or at least one warm thermal massdisposed within enclosure 101. For example, a cold phase change plate112 and/or a warm phase change plate 212 may be mounted withinenclosure, such as generally opposite door 103. Cold phase change plate112 may comprise a cold phase change material (PCM), which may include aeutectic material, having a desired melting point (e.g., about −5.5° C.(e.g., about 5.5° C. below 0° C.)). Warm phase change plate 212 maycomprise a warm phase change material, which may include a eutecticmaterial, having a desired melting point (e.g., about 15° C.).

Some example temperature controlled cargo containers may include one ormore thermal masses (e.g., cold phase change plates 112 and/or warmphase change plates 212) having sufficient thermal capacitance (e.g.,total energy capacity) to accommodate the total energy requirements of adesign condition. Some exemplary temperature controlled cargo containersmay include one or more thermal masses having sufficient surface areaand/or thermal conductivity to accommodate the peak heat transfer raterequirements of a design condition.

Some example phase change plates may be constructed from, for example,galvanized steel, aluminum, and/or stainless steel. In some exampleembodiments, such materials may be welded. An example phase change platemay have a generally flattened, rectangular shape with dimensions ofabout 4.5″×6.5″×40″. As used herein, “plate” refers to generallyrectangular shapes as well as any other desirable shape.

Some example temperature controlled cargo containers 100 according tothe present disclosure may be operated as follows. Warm phase changeplate 212 and/or cold phase change plate 112 may be conditioned. As usedherein, “conditioning” refers to freezing the cold phase change materialof cold phase change plate 112 and/or melting the warm phase changematerial of warm phase change plate 212. Product 106 may be placed ininterior storage space 104 of temperature controlled cargo container100. The temperature of interior storage space 104 may be controlled bycausing airflow across at least one of warm phase change plate 212 andcold phase change plate 112. Specifically, airflow across cold phasechange plate 112 may cool interior storage space 104 and/or airflowacross warm phase change plate 212 may warm interior storage space 104.

In some example temperature controlled cargo containers 100, one or morephase change plates 112, 212 may be mounted such that they are at leastpartially thermally insulated from one or more other phase change plates112, 212 and/or from interior storage space 104. For example, a dividerwall 107, which may be insulated, may interpose cold phase change plate112 and warm phase change plate 212. An interior separator wall 105,which may be insulated, may at least partially interpose interiorstorage space 104 and cold phase change plate 112 and/or warm phasechange plate 212. Thus, in some example embodiments, interior storagespace 104 may be generally rectangular and/or may be substantiallydefined by door 103, walls 102, and/or interior separator wall 105.Interior separator wall 105 may not extend fully between walls 102,thereby allowing thermal communication between interior space 104 andphase change plates 112, 212 when desired.

In some example temperature controlled cargo containers 100, one or morecooling fans 108 may be selectively operable to cause flow of air 110past a cold thermal mass, such as cold phase change plate 112, and/orone or more warming fans 208 may be selectively operable to cause flowof air 210 past a warm thermal mass, such as warm phase change plate212. As illustrated in FIGS. 3-8, fans 108, 208 may be arranged draw air110, 210 from interior storage space 104, through separator wall 105,and past phase change plate 112, 212 and/or to discharge air 110, 210into interior storage space 104. Some example embodiments may include atleast two cooling fans 108 and/or at least two warming fans 208, whichmay allow continued operation of temperature controlled cargo container100 if one of cooling fans 108 and/or one of warming fans 208 fails.Some example cooling fans 108 and/or warming fans 208 may include fansdriven by low voltage DC motors.

Some example temperature controlled cargo containers 100 may beconfigured to selectively direct air flow 110, 210 past one or morephase change plates 112, 212 such that the air 110, 210 passes along oneside of phase change plate 112, 212 in a first direction and passesalong an opposite side of phase change plate 112, 212 in an oppositedirection. For example, referring to FIGS. 3-5, air 110 may flowgenerally downward along a front face 112A of cold phase change plate112 and may flow generally upward along a rear face 112B of cold phasechange plate 112. Similarly, referring to FIGS. 6-8, air 210 may flowgenerally upward along a front face 212A of warm phase change plate 212and may flow generally downward along a rear face 212B of warm phasechange plate 212. The present disclosure contemplates that such a flowarrangement may reduce the temperature variation in the phase changematerials within cold phase change plate 112 and/or warm phase changeplate 212 as measured along axes generally parallel with the air flow.

Some exemplary temperature controlled cargo containers may be designedto reduce natural convection (e.g., fluid motion caused by densitydifferences in the fluid due to temperature gradients) past one or morephase change plates 112, 212. For example, referring to FIG. 3, anupwardly extending wall 114 (which may be referred to as a “false wall”)may be provided near cold phase change plate 112, such as between coldphase change plate 112 and separator wall 105. Wall 114 may preventcooler, denser air near the cold phase change plate 112 from settlinginto the interior storage space 104. Similarly, referring to FIG. 6, adownwardly extending wall 214 (which may be referred to as a “falsewall”) may be provided near warm phase change plate 212, such as betweenwarm phase change plate 212 and separator wall 105. Wall 214 may preventwarmer, less dense air near the warm phase change plate 212 from risinginto the interior storage space 104. Such walls 114, 214 may shape therespective air flow paths into P-traps 114A, 214A. Some exampleembodiments may direct air flow in a generally serpentine path pastphase change plates 112, 212. In some example embodiments, walls 105,114, 214 and/or phase change plates 112, 212 may provide a generallyS-shaped serpentine air flow path.

Some exemplary embodiments may reduce natural convection using one ormore devices in addition to or instead of a P-trap. For example, someexample embodiments may include one or more dampers and/or shutters,which may be selectively opened and/or shut by pneumatic, spring,electromechanical (such as solenoid or motor) and/or other similaractuators. Such dampers and/or shutters may be mounted to obstruct anatural convection flow path, such as adjacent to separator wall 105.

For example, as shown in FIGS. 4 and 5, natural convection may besignificantly reduced when desired by providing a flapper valve 115disposed in the airflow path. Flapper valve 115 may be hingedly attachedto a flapper valve support 119 which may be installed near the coldphase change plate 112. In one embodiment, the flapper valve 115 andflapper valve support may be disposed substantially above the upwardlyextending wall 114. The flapper valve 115 may also include a flappervalve backer 117 that may contact and may assist with the closing ofvalve 115 when desired. In one embodiment, as shown in FIGS. 5 and 6,flapper valve backer 117 may be disposed on the top end of upwardlyextending wall 114 substantially aligned with and underneath flappervalve 115 and may be separated from the flapper valve by a portion ofthe airflow path. As shown in FIG. 4, when the cooling fan 108 isoperating causing the air 110 to flow near the cold phase change plate112 in a generally serpentine air flow path the air may flow withsufficient pressure to open the flapper valve 115 and pivot it away fromflapper valve backer 117 so as to allow airflow to pass between theflapper valve 115 and the backer 115. As shown in FIG. 5, when thecooling fan 108 is off, the airflow caused by the fan substantiallyceases allowing the flapper valve 115 to close and contact flapper valvebacker 115. As shown in FIG. 5, when the flapper valve 115 is closed itmay substantially block the air flow path 110. As such, when additionalcooling in the interior storage space 104 is no longer required, and thecooling fan 108 is shut off, the flapper valve 115 closes against thebacker 117 to obstruct convection from the cooling plate 112 into theinterior storage space 104.

Similarly, as shown in FIGS. 6 and 7, natural convection may besignificantly reduced when desired by providing a flapper valve 215disposed in the airflow path near the warm phase change plate 212.Flapper valve 215 may be hingedly attached to a flapper valve support219 which may be installed near the warm phase change plate 212. In oneembodiment, the flapper valve 215 and flapper valve support may bedisposed substantially above the interior separator wall 105. Just aswith the flapper valve near the cold phase change plate 112, the flappervalve 215 may also include a flapper valve backer 217 that may contactand may assist with the closing of valve 215 when desired. In oneembodiment, as shown in FIGS. 7 and 8, flapper valve backer 217 may bedisposed on the top end of interior separator wall 105 substantiallyaligned with and underneath flapper valve 215 and may be separated fromthe flapper valve by a portion of the airflow path. As shown in FIG. 6,when the warming fan 208 is operating causing the air 210 to flow nearthe warm phase change plate 212 in a generally serpentine air flow paththe air may flow with sufficient pressure to open the flapper valve 215and pivot it away from flapper valve backer 217 so as to allow airflowto pass between the flapper valve 215 and the backer 215. As shown inFIG. 7, when the warming fan 208 is off, the airflow caused by the fansubstantially ceases allowing the flapper valve 215 to close and contactflapper valve backer 215. As shown in FIG. 7, when the flapper valve 215is closed it may substantially block the air flow path 210. As such,when additional warming in the interior storage space 104 is no longerrequired, and the warming fan 208 is shut off, the flapper valve 215closes against the backer 217 to obstruct convection from the warmingplate 212 into the interior storage space 104.

Any number of sufficiently resilient and flexible materials may beselected for the flapper valve 115, 215 including but not limited to avariety of plastics, rubber, silicon rubber, elastomers, or coatedfabrics. To provide additional force to releasably close the flappervalve 115, 215 when the circulating fans 108, 208 stop operating and itis desired to close the flapper valves, the flapper valves 115, 215 maybe at least partially comprised of ferrous material and the flappervalve backer 117, 217 may include a magnet that attracts and assistswith drawing the flapper valves 115, 215 against the flapper valvebacker 117, 217. It should be understood that the magnetic components offlapper valve 115, 215 and flapper valve backer 117, 217 could bereversed such that the flapper valve 115, 215 includes a magnet and theflapper valve backers 117, 217 include ferrous material that would causethe flapper valve 115, 215 with magnets to pull and attach to thebackers 117, 217 when the circulating fan 108, 208 is stopped. It iscontemplated that various known cooperative magnetic arrangements may beemployed such as varying the magnetic strength of the backer 117, 217 orflapper valve 115, 215 at different points of an associated magnet tooptimize the ability of the valve 115, 215 to stay open duringcirculating fan 108, 208 operation and to close when the fan operationis stopped.

Walls 102 may be insulated, such as by vacuum panels. In some exampleembodiments, walls 102 may have a thickness 401 of about 4″ and/or mayhave an R-value (a measure of thermal resistance) of about R-70 toresist thermal energy transfer between interior storage space 104 andthe ambient environment. Referring to FIG. 9, an example wall mayinclude an exterior skin 402 and/or an interior skin 404. Exterior skin402 and/or interior skin 404 may comprise aluminum and/or may have athickness of about 0.030″, for example. An insulating foam layer, suchas poured foam 406, may be provided adjacent to exterior skin 402.Poured foam 406 may have a thickness 408 of about 2″, for example. Avacuum panel 410 may be provided adjacent to poured foam 406. Vacuumpanel 410 may have a thickness 412 of about 1″, for example. Aninsulating foam layer, such as poured foam 414, may be provided betweenvacuum panel 410 and interior skin 404. Poured foam 414 may have athickness 416 of about ½″ or about ¾″, for example. In some exampleembodiments, poured foam 414 may be replaced by a foam board, which maybe bonded to vacuum panel 410 and/or interior skin 404, such as using anadhesive.

In some example temperature controlled cargo containers 100, walls 102may comprise a stressed skin construction, which may provide arelatively high strength with relatively low weight. In some exampleembodiments, inner layers (e.g., poured foam 406, vacuum panel 410,and/or poured foam 414) and/or outer layers (e.g., exterior skin 402and/or interior skin 404) may be disposed such that layers may not sliderelative to others layer. Such a construction may provide a wallstructure having relatively high area moment of inertia, which may addconsiderable structural strength to the product with minimal additionalweight, while allowing a “flex” component to the structure.

Some exemplary temperature controlled cargo containers 100 may includeone or more thermal masses including one or more augmented surfaces,such as fins and/or other similar heat transfer enhancing features,internally and/or externally. For example, referring to FIG. 10, anexample phase change plate 302 may include one or more thermallyconductive fins 304 extending through the thickness 306 of the plate302, such as substantially from one wall 308 to the opposite wall 310,which may enhance heat transfer to and/or from phase change material 312(e.g., a eutectic solution and/or other phase change material) betweenwalls 308, 310. In some exemplary embodiments, one or more fins 304 maybe mounted to the first wall 308 and may seat against the second wall310 when the phase change plate 302 is assembled.

It is within the scope of the disclosure to utilize fins 304 or otherconductive augmentations of any cross section or profile. The presentdisclosure contemplates that some example phase change materials may berelatively poor thermal conductors and that utilizing conductiveaugmentations within the phase change material may reduce thetemperature gradient across the thickness of the phase change material.Some example phase change plates may include refrigerant lines (and/orlines for other materials used to condition phase change materials)and/or electrical resistance heaters extending therethrough forconditioning the phase change material.

FIG. 11 is a schematic diagram of an example refrigeration system 500which may be used in connection with an example temperature controlledcargo container 100. In some example embodiments, refrigeration system500 may include two substantially independent refrigeration units 500A,500B, thus providing redundancy. Refrigeration units 500A, 500B may besubstantially identical and, for purposes, of clarity, FIG. 11 isdiscussed with reference to refrigeration unit 500A with theunderstanding that refrigeration unit 500B may include correspondingcomponents. An individual refrigeration unit 500A may include acompressor 504, a condenser 506, a fan 508 configured to provide airflowacross condenser 506, and/or an expansion valve 512.

In some example embodiments, an individual refrigeration unit 500A mayinclude an evaporator 502 disposed in thermal communication with one ormore cold phase change plates 112 (e.g., with evaporator coils extendingthrough the interior of cold phase change plate 112). In some exampleembodiments, evaporators 502 associated with more than one individualrefrigeration unit 500A, 500B may be in thermal contact with the samecold phase change plate 112, which may increase the reliability oftemperature controlled cargo container 100 because the failure of asingle refrigeration unit 500A, 500B may not prevent cold phase changeplate 112 from being conditioned. Each of refrigeration units 500A, 500Bmay be sized to be capable of conditioning one or more cold phase changeplates 112 without the other system operating. However, the time tocondition one or more cold phase change plates 112 with a singlerefrigeration unit 500A, 500B operating may be longer than the time tocondition one or more cold phase change plate 112 with bothrefrigeration units 500A, 500B operating. In some example embodiments,one or more cold phase change plates 112 and/or evaporator 502 may belocated within enclosure 101 and/or many of the remaining components ofrefrigeration units 500A, 50013 may be disposed in equipment section111.

FIG. 12 is a schematic diagram of an example electrical system 600associated with a temperature controlled cargo container 100 accordingto the present disclosure. An external power source connection 602 mayprovide power to one or more power supplies 604, 606, 608 and/or abattery charger 610. Power supply 604 may feed refrigeration unit 500Aand/or warm plate regenerator 612 (e.g., an electrical resistance heaterin thermal contact with warm phase change plate 212). Power supply 606may feed refrigeration unit 500B and/or warm plate regenerator 614.Battery charger 610 may provide a charging current to rechargeablebattery 616, which may feed control electronics 618, warming fans 208A,20813, and/or cooling fans 108A, 108B. Power supply 608 may also feedcontrol electronics 618, warming fans 208A, 208B, and/or cooling fans108A, 108B.

Some example temperature controlled cargo containers 100 may be operablein a recharge mode (also referred to as an active mode) and/or atransport move (also referred to as a passive mode). In an examplerecharge mode, a temperature controlled cargo container 100 mayconnected to an external power source, such as standard electric linepower (e.g., 100-230 VAC, 50 or 60 Hz).

In the recharge mode, refrigeration units 500A, 500B may cool cold phasechange plate 112, which may freeze the cold phase change material ofcold phase change plate 112. Similarly, one or more warm plateregenerators 612, 614 (e.g., electrical resistance heaters) may heatwarm phase change plate 212, which may melt the warm phase changematerial of warm phase change plate 212. Refrigeration units 500A, 500Band/or regenerators 612, 614 may be powered from the external powersource. Rechargeable battery 616 (such as a 12 V lead-acid battery) maybe charged from the external power source. In some example embodiments,the components within box 620 as well as the components within box 622of FIG. 12 may be powered from the external power source when in therecharge mode.

Referring to FIG. 13, some example temperature controlled cargocontainers according to the present disclosure may be constructed tointerface with external conditioning systems. Such embodiments may ormay not include refrigeration units 500A, 500B, warm plate regenerators612, 614, and/or equipment section 111. As illustrated in FIG. 13, anexample temperature controlled cargo container 100A holding product 106Amay be generally similar to temperature controlled cargo container 100described above. Temperature controlled cargo container 100A may beconfigured for use with externally supplied conditioning for cold phasechange plate 112A and/or warm phase change plate 212A. For example, coldphase change plate 112A may be conditioned by a chilled fluid 802 (e.g.,a water-ethylene glycol solution at about −5° C.) circulated through aheat exchanger 800 in thermal contact with cold phase change plate 112A.Chilled fluid 802 may be propelled by a pump 804 via through appropriateconduits, which may include fittings 806, 808 (e.g., quick disconnectfittings). A refrigeration system 810, which may be powered from anexternal power source 812, may remove heat from chilled fluid 802 usinga heat exchanger 814. In some example embodiments, refrigeration system810 may include one or more vapor-compression refrigeration systems,which may be generally similar to refrigeration units 500A, 500B.

Similarly, warm phase change plate 212A may be conditioned by a warmedfluid 902 (e.g., a water-ethylene glycol solution at about 25° C.)circulated through a heat exchanger 900 in thermal contact with warmphase change plate 212A. Warmed fluid 902 may be propelled by a pump 904via through appropriate conduits, which may include fittings 906, 908(e.g., quick disconnect fittings). A heater system 910, which may bepowered from an external power source 912, may remove heat from chilledfluid 902 using a heat exchanger 914. In some example embodiments,heater system 910 may include one or more electrical resistance heatersin thermal contact with warmed fluid 902 in heat exchanger 914.

Referring to FIG. 14, Some example temperature controlled cargocontainers 100B according to the present disclosure may include one ormore readily removable and/or replaceable cold phase change plates 112Band/or warm phase change plates 212B. Such example embodiments may allowpre-conditioned cold phase change plates 112B and/or warm phase changeplates 212B to be installed into temperature controlled cargo container100B prior to transport. In addition, such embodiments may permitreplacement of partially or fully expended cold phase change plates 112Band/or warm phase change plates 212B with conditioned cold phase changeplates 112B and/or warm phase change plates 212B during extended storageand/or during extended transport. Such embodiments may or may notinclude refrigeration units 500A, 500B, warm plate regenerators 612,614, and/or equipment section 111. For example, removable cold phasechange plates 112B may be conditioned in an environmental chamber 1002(which may be maintained at about −5° C.) and/or removable warm phasechange plates 212B may be conditioned in an environmental chamber 1004(which may be maintained at about 15° C.).

In an example transport mode, some example temperature controlled cargocontainers 100 may be disconnected from the external power source and/orconditioning source. In the transport mode, the temperature of interiorstorage space 104 may be monitored, and one or more of fans 108A, 108B,208A, 208B may be selectively operated to circulate air across one ormore cold phase change plates 112 and/or one or more warm phase changeplates 212 as necessary to maintain the temperature of interior storagespace 104 within a prescribed temperature band (e.g., between about 2°C. and about 8° C.). For example, if the temperature within the interiorstorage space 104 exceeds a predetermined setpoint, fans 108A, 108B maybe operated to circulate air across cold phase change plate 112, whichmay cool interior storage space 104. Similarly, if the temperaturewithin interior storage space 104 drops below a predetermined setpoint,fans 208A, 208B may be operated to circulate air across warm phasechange plate 212, which may warm interior storage space 104. Morespecifically, circulation of air across cold phase change plate 112 maytransfer heat from the air to the cold phase change material, which maycause the cold phase change material to melt. As the cold phase changematerial melts, it may absorb from the air an amount of heat equal toits latent heat of fusion. Similarly, circulation of air across warmphase change plate 212 may transfer heat from the warm phase changematerial to the air, which may cause the warm phase change material tofreeze. As the warm phase change material freezes, it may transfer tothe air an amount of heat equal to it latent heat of fusion.

Control electronics 618 (e.g., temperature monitoring components, fancontrol components, etc.) and/or fans 108A, 108B, 208A, 208B may bepowered from the rechargeable battery 616 in the transport mode. In someexample embodiments, refrigeration units 500A, 500B used to cool coldphase change plates 112 and/or the regenerator used to heat warm phasechange plates 212 may not operate during transport mode. In some exampleembodiments, the components within box 622 of FIG. 12 may be poweredfrom battery 616 during the transport mode.

In some example embodiments, various control electronics 618 (which mayinclude a status panel) may be powered from rechargeable battery 616during the transport mode. The control electronics may include, forexample, a low power embedded industrial PC for low power consumptionand/or low EMI (electromagnetic interference). The control electronicsand/or status panel may be configured to communicate the condition ofthe cargo unit to the user. For example, a temperature of the interiorstorage space 104 may be displayed and/or transmitted to a user. In someexample embodiments, a data logger may monitor and/or record thetemperature in the interior storage space 104. In some exampleembodiments, the data logger may be independently powered by anon-replaceable battery with an extended life, such as a three yearlife.

Some exemplary temperature controlled cargo containers according to thepresent disclosure may be configured to be received within and/or on anair transport cargo unit for shipment via air. For example, twoexemplary 76 cubic foot capacity temperature controlled cargo containers100 may be placed inside an L9 unit load device (ULD) for shipmentaboard certain types of aircraft. Similarly, as illustrated in FIG. 15,some example temperature controlled cargo containers 100 may betransported in a net/pallet configuration. One or more temperaturecontrolled cargo containers 100 may be placed on a generally flat pallet700, which may be referred to as a “cookie sheet” in the air transportindustry. Temperature controlled cargo containers 100 may be fastened topallet 700 using, for example, one or more straps 702 and/or nets 704.Pallet 700 with temperature controlled cargo containers 100 thereon maybe considered a ULD for air transport purposes and/or may be readilyloaded into and secured within an aircraft (or other vehicle).

Some example temperature controlled cargo containers 100 according tothe present disclosure may be configured to function as a ULD in an airtransport system. Such example embodiments may be sized and/or shapedsubstantially the same as a ULD used by an air carrier, and the aircarrier may load such temperature controlled cargo containers 100 in anaircraft in generally the same manner as other ULDs.

Some example temperature controlled cargo containers 100 may be sized toreceive standard units of product. For example, an example 76 cubic footcapacity temperature controlled cargo container 100 may include aninterior storage space 104 sized to receive an about 40″×48″palletcontaining about 250 lbs. of product. In such an example embodiment,interior storage space 104 may have interior dimensions of about 46″high×44″ wide×53″ deep. Such an example embodiment may have overalldimensions of about 58″ high×52.75″ wide×80″ long, and its tare weightmay be about 1250 lbs.

Some example thermal masses comprising phase change materials mayinclude one or more of water, potassium nitrate, ethylene glycol,propylene glycol, one or more alcohols (e.g., ethyl alcohol, methylalcohol, and/or isopropyl alcohol), potassium chloride, sodium borate,zinc, and/or ammonium chloride. In general, it is within the scope ofthe present disclosure to utilize one or more thermal masses comprisingany materials capable of accepting and/or delivering appropriate amountsof thermal energy at appropriate rates to satisfy design conditions.Further, it is within the scope of the present disclosure to utilize anyphase change materials providing desired melting points.

Some example temperature controlled cargo containers have been describedherein with reference to a target temperature of about 5° C., which maycorrespond to temperature range of about 2° C. to about 8° C. Otherexample temperature controlled cargo containers according to the presentdisclosure may be configured to maintain a product located therein atcolder temperatures (e.g., about −20° C., about −40° C., about −80° C.,and/or about −100° C.) or warmer temperatures (e.g., about 25° C., about50° C., and/or about 60° C.). In general, temperature controlled cargocontainers according to the present disclosure may be configured tomaintain any desired interior temperature.

Some example temperature controlled cargo containers according to thepresent disclosure may include warm and cold thermal masses includingphase change materials having melting points differing from a targettemperature by various amounts. For example, a warm phase changematerial may have a melting point about 15° C. above a targettemperature and a cold phase change material may have a melting pointabout 15° C. below the target temperature. Similarly, the melting pointsof the warm and cold phase change materials may differ from the targettemperature by any other desired amount (e.g., about 5° C., about 10°C., about 20° C., about 25° C., etc.). In some example embodiments, themelting point of the warm phase change material may differ from thetarget temperature by a greater (or lesser) amount than the cold phasechange material differs from the target temperature. For example, a warmphase change material may have a melting point of about 10° C. aboutabove a target temperature and a cold phase change material may have amelting point of about 20° C. below the target temperature.

Some example temperature controlled cargo containers may be operated asfollows. A refrigeration system may be operated to cool a cold phasechange plate associated with an interior storage space of a container. Aheater may be operated to heat a warm phase change plate associated withthe interior storage space. A product may be placed in the interiorstorage space. A temperature associated with the interior storage spacemay be measured. At least one fan may be selectively operated to causeairflow across at least one of the cold phase change plate and the warmphase change plate if the temperature associated with the interiorstorage space departs from a predetermined temperature range.

As used herein, ambient conditions refer to the environmental conditionsto which a temperature controlled cargo container is subject. Forexample, the ambient temperature for a temperature controlled cargocontainer on an airport ramp may be the outside air temperature at theramp. As another example, the ambient temperature for a temperaturecontrolled cargo container being transported in an aircraft at cruisealtitude may be the interior temperature of the aircraft where thetemperature controlled cargo container is stowed.

While exemplary embodiments have been set forth above for the purpose ofdisclosure, modifications of the disclosed embodiments as well as otherembodiments thereof may occur to those skilled in the art. Accordingly,it is to be understood that the disclosure is not limited to the aboveprecise embodiments and that changes may be made without departing fromthe scope. Likewise, it is to be understood that it is not necessary tomeet any or all of the stated advantages or objects disclosed herein tofall within the scope of the disclosure, since inherent and/orunforeseen advantages may exist even though they may not have beenexplicitly discussed herein.

1. A method of controlling the temperature of a product, the methodcomprising: placing a product in an interior storage space of acontainer, the container comprising an enclosure including insulatedwalls, wherein the interior storage space is within the enclosure,wherein the container includes a warm phase change plate and a coldphase change plate, and wherein each of the warm phase change plate andcold phase change plate is disposed within the enclosure and is arrangedfor selective heat exchange with the interior storage space, and whereinat least one flapper valve is arranged to selectively permit andobstruct airflow about at least one of said warm phase change plate andsaid cold phase change plate; and controlling a temperature of theproduct by at least one of raising a temperature of the interior storagespace by recirculating across the warm phase change plate withoutsubstantial air flow across the cold phase change plate, and loweringthe temperature of the interior storage space by recirculating airacross the cold phase change plate without substantial air flow acrossthe warm phase change plate.
 2. The method of claim 1, whereincontrolling the temperature of the interior storage space includessensing a temperature associated with the product; wherein lowering thetemperature of the interior storage space comprises, if the temperatureassociated with the product is above a target temperature range,operating a cooling fan associated with causing air flow across the coldphase change plate to draw air from the interior storage space through aseparator wall at least partially interposing the interior storage spaceand the cold phase change plate, opening one of said at least oneflapper valve and flowing the air past the cold phase change plate, anddischarging the air into the interior storage space; and wherein raisingthe temperature of the interior storage space comprises, if thetemperature associated with the product is below the target temperaturerange, operating a warming fan associated with causing air flow acrossthe warm phase change plate to draw air from the interior storage spacethrough a separator wall at least partially interposing the interiorstorage space and the warm phase change plate, opening one of said atleast one flapper valve and flowing the air past the warm phase changeplate, and discharging the air into the interior storage space.
 3. Themethod of claim 1, further comprising, prior controlling the temperatureof the product, conditioning at least one of the warm phase change plateand the cold phase change plate.
 4. The method of claim 3, whereinconditioning the cold phase change plate includes operating arefrigeration unit comprising at least one evaporator coil extendingthrough an interior of the cold phase change plate to cause freezing ofa cold phase change solution within the cold phase change plate; andwherein conditioning the warm phase change plate includes operating aheater in thermal contact with the warm phase change plate to melt awarm phase change solution within the warm phase change plate.
 5. Themethod of claim 1, wherein controlling the temperature of the productincludes directing the air flow along a first side of at least one ofthe warm phase change plate and the cold phase change plate in a firstdirection and directing the air flow along a second side of the at leastone of the warm phase change plate and the cold phase change plate in asecond direction; and wherein the second direction is substantiallyopposite the first direction.
 6. The method of claim 1, furthercomprising reducing natural circulation flow across at least one of thewarm phase change plate and the cold phase change plate.
 7. The methodof claim 6, wherein reducing natural circulation flow across at leastone of the warm phase change plate and the cold phase change plateincludes at least one of providing an air trap associated with at leastone of the warm phase change plate and the cold phase change plate andclosing said at least one flapper valve.
 8. The method of claim 7,wherein providing the air trap includes providing at least one of adownwardly extending wall at least partially interposing the warm phasechange plate and the interior storage space, and an upwardly extendingwall at least partially interposing the cold phase change plate and theinterior storage space.
 9. The method of claim 1, further comprisingtransporting the container from a first location to a second locationwhile the product remains within the interior storage space.
 10. Amethod of storing a product in a container, the method comprising:operating a refrigeration system comprising at least one evaporator coilextending through an interior of a cold phase change plate associatedwith an interior storage space of a container to cool the cold phasechange plate, wherein the container comprises an enclosure constructedof insulated walls, wherein the interior storage space is within theenclosure, wherein the cold phase change plate is disposed within theenclosure and is arranged for selective thermal communication with theinterior storage space, and wherein the refrigeration system is poweredfrom a first external source of electrical power; operating a heater inthermal contact with a warm phase change plate associated with theinterior storage space to heat the warm phase change plate, wherein thewarm phase change plate is disposed within the enclosure and is arrangedfor selective thermal communication with the interior storage space,wherein the heater is powered from the first external source ofelectrical power; placing a product in the interior storage space;disconnecting the refrigeration system and the heater from the firstexternal source of electrical power; and controlling a temperatureassociated with the interior storage space by measuring the temperatureassociated with the interior storage space; and selectively operating atleast one of a cooling fan arranged to cause airflow across the coldphase change plate and a warming fan arranged to cause airflow acrossthe warm phase change plate if the temperature associated with theinterior storage space departs from a predetermined temperature range,wherein the at least one cooling fan and the at least one warming fanare powered from a rechargeable battery associated with the container,and wherein at least one flapper valve is arranged to selectively permitand obstruct airflow about at least one of said warm phase change plateand said cold phase change plate where said at least one flapper valveis propelled to an open position when said at least one cooling fan orsaid at least one warming fan is operating; wherein the refrigerationunit and the heater are not operable while disconnected from the firstexternal source of electrical power.
 11. The method of claim 10, furthercomprising, prior to operating the refrigeration system and operatingthe heater, connecting the refrigeration system and the heater to thefirst external source of electrical power.
 12. The method of claim 11,further comprising, after disconnecting the refrigeration system and theheater from the first external source of electrical power, loading thecontainer into a vehicle.
 13. The method of claim 12, wherein loadingthe container into a vehicle includes loading the refrigeration systemand the heater into the vehicle, the refrigeration system and the heaterbeing mounted to the container.
 14. The method of claim 13, furthercomprising, transporting the container from a first location to a secondlocation using the vehicle; and at the second location, conditioning atleast one of the cold phase change plate and the warm phase changeplate.
 15. The method of claim 14, further comprising, prior toconditioning the at least one of the cold phase change plate and thewarm phase change plate at the second location, connecting at least oneof the refrigeration unit and the heater to a second external source ofelectrical power.
 16. The method of claim 15, wherein the containerfurther comprises an equipment section substantially adjacent to theenclosure; and wherein at least a portion of the refrigeration system isdisposed in the equipment section.
 17. A method of operating atemperature-controlled cargo container, the method comprising:conditioning a cold phase change plate disposed within an insulatedenclosure using a refrigeration system comprising at least oneevaporator coil extending through an interior of the cold phase changeplate, wherein the enclosure is a component of a temperature-controlledcargo container, and wherein the cold phase change plate comprises acold phase change solution having a cold phase change solution meltingpoint; conditioning a warm phase change plate disposed within theinsulated enclosure using a heater in thermal contact with the warmphase change plate, wherein an insulated divider wall interposes coldphase change plate and the warm phase change plate, and wherein the warmphase change plate comprises a warm phase change solution having a warmphase change solution melting point, and wherein the warm phase changesolution melting point is higher than the cold phase change solutionmelting point; receiving a product in an interior storage space of thetemperature-controlled cargo container, wherein the interior storagespace is disposed within the enclosure, and wherein the interior storagespace is arranged for selective heat exchange with the cold phase changeplate and the warm phase change plate; and controlling a temperatureassociated with the product while the refrigeration system and theheater are not operated, including monitoring the temperature associatedwith the product; if the temperature associated with the product risesabove a target temperature range, operating a cooling fan arranged tocause air flow across the cold phase change plate by drawing air fromthe interior storage space through a separator wall at least partiallyinterposing the interior storage space and the cold phase change plate,flowing the air past the cold phase change plate, and discharging theair into the interior storage space; and if the temperature associatedwith the product falls below the target temperature range, operating awarming fan associated with causing air flow across the warm phasechange plate by drawing air from the interior storage space through aseparator wall at least partially interposing the interior storage spaceand the warm phase change plate, flowing the air past the warm phasechange plate, and discharging the air into the interior storage space,and wherein at least one flapper valve is arranged to selectively permitand obstruct airflow about at least one of said warm phase change plateand said cold phase change plate where said at least one flapper valveis propelled to an open position when said at least one cooling fan orsaid at least one warming fan is operating.
 18. The method of claim 17,wherein at least one of the cold phase change solution and the warmphase change solution comprises a eutectic material.
 19. The method ofclaim 17, wherein controlling the temperature associated with theproduct includes directing the air flow along a first side of the warmphase change plate in a first direction and directing the air flow alonga second side of the warm phase change plate in a second direction; andwherein the second direction is substantially opposite the firstdirection.
 20. The method of claim 17, wherein controlling thetemperature associated with the product includes directing the air flowalong a first side of the cold phase change plate in a first directionand directing the air flow along a second side of the cold phase changeplate in a second direction; and wherein the second direction issubstantially opposite the first direction. 21-29. (canceled)